Busway Stab Assemblies and Related Systems and Methods

ABSTRACT

A plug-in device for use with a busway system comprising a busway housing defining a longitudinal axis includes a stab base housing having first and second opposite sides, one or more stab conductors extending out of and away from the stab base housing at each of the first and second sides of the stab base housing, and a ground conductor at an upper portion of the stab base housing. The stab base housing is configured to be received through an opening at a bottom portion of the busway housing and positioned in a first position and then rotated from the first position to a second position. The ground conductor is configured to contact a top wall of the busway housing in each of the first and second positions.

RELATED APPLICATIONS

This is a continuation of U.S. application Ser. No. 15/587,731, filed onMay 5, 2017, the disclosure of which is incorporated by reference in itsentirety.

BACKGROUND

Busway systems typically include several elongated busway sections withbusway joints between adjacent busway sections. The busway joint servesto electrically and mechanically connect the adjacent busway sections.Continuous plug-in busway systems allow for plug-in devices (e.g.,outlet boxes) to be installed anywhere or substantially anywhere alongthe length of the busway sections.

SUMMARY

Some embodiments of the invention are directed to a plug-in device foruse with a busway system including a busway housing defining alongitudinal axis. The device includes a stab base housing having firstand second opposite sides, one or more stab conductors extending out ofand away from the stab base housing at the first side of the stab basehousing, one or more stab conductors extending out of and away from thestab base housing at the second side of the stab base housing, and aground conductor at an upper portion of the stab base housing. The stabbase housing is configured to be received through an opening at a bottomportion of the busway housing and positioned in a first position witheach stab conductor extending away from the stab base housing in adirection substantially parallel to the longitudinal axis of the buswayhousing and with the ground conductor contacting a top wall of thebusway housing. The stab base housing is configured to be rotated fromthe first position to a second position with each stab conductorextending away from the stab base housing in a direction substantiallyperpendicular to the longitudinal axis of the busway housing and withthe ground conductor contacting the top wall of the busway housing.

The ground conductor may extend upwardly from the upper portion of thestab base housing above a top of the stab base housing. The groundconductor may be resilient and configured to deform downwardly inresponse to contacting the top wall of the busway housing.

The stab base housing may include first and second opposing walls witheach of the first and second walls extending between the first andsecond sides of the stab base housing. The plug-in device may include acable management member in an interior cavity of the stab base housing.The cable management member may include a central portion, a first sideportion extending away from the central portion at one side thereof, anda second side portion extending away from the central portion at anopposite side thereof. The first side portion of the cable managementmember may be coupled to the first wall of the stab base housing and thesecond side portion of the cable management member may be coupled to thesecond wall of the stab base housing.

The plug-in device may include a first cable having a first endelectrically connected to the ground conductor and a second, oppositeend extending out of a bottom portion of the stab base housing. Thecable management member central portion may define an elongatepassageway. The first cable may be received in the passageway of thecable management member.

The one or more stab conductors extending out of and away from the stabbase housing at the first side of the stab base housing may includefirst and second phase conductors. The one or more stab conductorsextending out of and away from the stab base housing at the second sideof the stab base housing may include a third phase conductor.

The plug-in device may include: a first cable having a first endelectrically connected to the first phase conductor and a second,opposite end extending out of a bottom portion of the stab base housing;a second cable having a first end electrically connected to the secondphase conductor and a second, opposite end extending out of the bottomportion of the stab base housing; and/or a third cable having a firstend electrically connected to the third phase conductor and a second,opposite end extending out of the bottom portion of the stab basehousing.

The first cable may extend external to and along one of the first andsecond side portions of the cable management member. The second cablemay extend external to and along the other one of the first and secondside portions of the cable management member.

The one or more stab conductors extending out of and away from the stabbase housing at the second side of the stab base housing may include athird phase conductor and a neutral conductor. The plug-in device mayinclude a fourth cable having a first end electrically connected to theneutral conductor and a second, opposite end extending out of the bottomportion of the stab base housing. The third cable may extend along oneof the first and second side portions of the cable management member.The fourth cable may extend along the other one of the first and secondside portions of the cable management member.

The first and second side portions of the cable management member mayeach include a laterally extending side with first face and a secondopposite face. The first cable may extend along the first face of one ofthe first and second side portions of the cable management member. Thethird cable may extend along the second face of one of the first andsecond side portions of the cable management member.

In some embodiments, an enclosure is coupled to a lower portion of thestab base housing. A cable may extend from each stab conductor and fromthe ground conductor to outside the stab base housing at the lowerportion thereof. Each cable may be electrically connected to componentsin the enclosure.

In some embodiments, each stab conductor is L-shaped with a firstportion and a second portion that is perpendicular to the first portion.The first portion of each stab conductor may extend out of and away fromthe stab base housing. The second portion of each stab conductor may beat least partially held in a channel defined in the stab base housing.

Some other embodiments of the invention are directed to a busway system.The system includes a busway section. The busway section includes abusway housing defining a longitudinal axis, with the busway housingincluding first and second opposite side portions. The busway sectionincludes a first insulator held in the first side portion of the buswayhousing, with the first insulator holding one or more bus barconductors. The busway section includes a second insulator held in thesecond side portion of the busway housing, with the second insulatorholding one or more bus bar conductors. The system includes a plug-indevice. The plug-in device includes a stab base housing having first andsecond opposite sides, one or more stab conductors extending out of andaway from the stab base housing at the first side of the stab basehousing, one or more stab conductors extending out of and away from thestab base housing at the second side of the stab base housing, and aground conductor extending upwardly out of an opening at an upperportion of the stab base housing. The stab base housing is configured tobe received through an opening at a bottom portion of the busway housingand positioned in a first position with each stab conductor extendingaway from the stab base housing in a direction substantially parallel tothe longitudinal axis of the busway housing and the ground conductorcontacting a top wall of the busway housing. The stab base housing isconfigured to be rotated from the first position to a second positionwith each stab conductor extending away from the stab base housing in adirection substantially perpendicular to the longitudinal axis of thebusway housing to electrically connect each stab conductor with one ofthe bus bar conductors.

In some embodiments, the ground conductor extends above a top of thestab base housing and is resilient and configured deform upwardly anddownwardly in response to contacting the top wall of the busway housing.

A cable management member may be positioned in an interior cavity of thestab base housing. The ground conductor may include an arcuate centerportion and first and second side portions that are attached to the stabbase housing above the cable management member. A first cable may beelectrically connected to the lower surface of the ground conductor. Thefirst cable may extend downwardly through a channel defined in a centralportion of the cable management member and out of a lower portion of thestab base housing.

The one or more stab conductors extending out of and away from the stabbase housing at the first side of the stab base housing may includefirst and second phase conductors. The one or more stab conductorsextending out of and away from the stab base housing at the second sideof the stab base housing may include a third phase conductor. The cablemanagement member may include a first side portion extending outwardlyaway from a first side of the central portion and a second side portionextending outwardly away from a second, opposite side of the centralportion. A second cable may be electrically connected to a the firstphase conductor, a third cable may be electrically connected to thesecond phase conductor, and a fourth cable may be electrically connectedto the third phase conductor. The second cable may extend along a firstface of the first side portion of the cable management member and out ofthe lower portion of the stab base housing. The third cable may extendalong a first face of the second side portion of the cable managementmember and out of the lower portion of the stab base housing. The fourthcable may extend along either a second, opposite face of the first sideportion of the cable management member or a second, opposite face of thesecond side portion of the cable management member and out of the lowerportion of the stab base housing.

Each bus bar conductor held in the first insulator may include an upperportion and an opposite lower portion. Each bus bar conductor held inthe second insulator may include an upper portion and an opposite lowerportion. In the second position, each one of the stab conductorsextending out of and away from the stab base housing at the first sideof the stab base housing may be received between and contact the upperand lower portions of one of the bus bar conductors held in the firstinsulator to be electrically connected therewith. In the secondposition, each one of the stab conductors extending out of and away fromthe stab base housing at the second side of the stab base housing may bereceived between and contact the upper and lower portions of one of thebus bar conductors held in the second insulator to be electricallyconnected therewith.

In some embodiments, each of the stab conductors includes an end portionthat is tapered such that the end portion narrows in thickness from acentral portion to an end of the stab conductor.

The stab base housing may include a first alignment tab on the firstside of the stab base housing and a second alignment tab on the secondside of the stab base housing. The first alignment tab may have a firstlength and the second alignment tab may have a second length that isgreater than the first length. The busway housing may include a firstchannel and a second channel at the bottom portion of the buswayhousing. The first channel may have a first depth and the second channelmay have a second depth that is greater than the first depth. The firstalignment tab may be received in the first channel and the secondalignment tab may be received in the second channel when the stab basehousing is in the second position.

Some other embodiments of the invention are directed to a method. Themethod includes providing a busway section. The busway section includes:a busway housing defining a longitudinal axis, with the busway housingincluding first and second opposite side portions; a first insulatorheld in the first side portion of the busway housing, with the firstinsulator holding one or more bus bar conductors; and a second insulatorheld in the second side portion of the housing, with the secondinsulator holding one or more bus bar conductors. The method includesproviding a plug-in device. The plug-in device includes: a stab basehousing having first and second opposite sides; one or more stabconductors extending out of and away from the stab base housing at thefirst side of the stab base housing; one or more stab conductorsextending out of and away from the stab base housing at the second sideof the stab base housing; and a ground conductor extending upwardly outof an opening at a top of the stab base housing. The method includesreceiving the stab base housing through an opening at a bottom portionof the busway housing in a first position with each stab conductorextending away from the stab base housing in a direction substantiallyparallel to the longitudinal axis of the busway housing and with theground conductor contacting a top wall of the busway housing. The methodincludes rotating the stab base housing from the first position to asecond position with each stab conductor extending away from the stabbase housing in a direction substantially perpendicular to thelongitudinal axis of the busway housing.

In some embodiments, rotating the stab base housing from the firstposition to the second position includes electrically connecting eachone of the stab conductors to one of the bus bar conductors.

Further features, advantages and details of the present invention willbe appreciated by those of ordinary skill in the art from a reading ofthe figures and the detailed description of the preferred embodimentsthat follow, such description being merely illustrative of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a stab base assembly according to someembodiments.

FIG. 2 is another perspective view of the stab base assembly of FIG. 1.

FIG. 3 is a front view of the stab base assembly of FIG. 1.

FIG. 4 is a side view of the stab base assembly of FIG. 1.

FIG. 5 is a perspective view of a first housing portion of the stab baseassembly of FIG. 1.

FIG. 6 is a side view of the first housing portion of FIG. 5.

FIG. 7 is a perspective view of a second housing portion of the stabbase assembly of FIG. 1.

FIG. 8 is a side view of the second housing portion of FIG. 7.

FIG. 9 is a perspective view of a cable management member according tosome embodiments.

FIG. 10 is a top view of the cable management member of FIG. 9.

FIG. 11 is a perspective view of a stab conductor according to someembodiments.

FIGS. 12A-12C illustrate arrangements for electrically connecting acable and a stab conductor according to various embodiments.

FIG. 13 is a sectional view of the stab base assembly of FIG. 1.

FIG. 14 is a perspective view of a ground conductor according to someembodiments.

FIG. 15 illustrates a cable electrically connected to the groundconductor of FIG. 14.

FIG. 16 is a sectional view of the stab base assembly of FIG. 1.

FIG. 17 is a perspective view of a plug-in device including the stabbase assembly of FIG. 1 according to some embodiments.

FIG. 18 is an exploded perspective view of a busway system according tosome embodiments.

FIG. 19 is an exploded perspective view of a busway section according tosome embodiments.

FIG. 20 is a perspective view of a housing of the busway section of FIG.19.

FIG. 21 is an end view of the housing of FIG. 20.

FIG. 22 is a perspective view of an insulator of the busway section ofFIG. 19.

FIG. 23 is an end view of the insulator of FIG. 22.

FIG. 24 is a perspective view of a housing holding two insulators of thebusway section of FIG. 19.

FIG. 25 is a perspective view of a bus bar conductor of the buswaysection of FIG. 19.

FIG. 26 is an end view of the conductor of FIG. 25.

FIG. 27 is an end view of the busway section of FIG. 19 in an assembledstate.

FIG. 28 illustrates the plug-in device of FIG. 17 positioned below thebusway section of FIG. 27.

FIG. 29 illustrates the plug-in device positioned in the busway sectionof FIG. 27 in a first position.

FIG. 30 illustrates the plug-in device positioned in the busway sectionof FIG. 27 in a second position.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which illustrativeembodiments of the invention are shown. In the drawings, the relativesizes of regions or features may be exaggerated for clarity. Thisinvention may, however, be embodied in many different forms and shouldnot be construed as limited to the embodiments set forth herein; rather,these embodiments are provided so that this disclosure will be thoroughand complete, and will fully convey the scope of the invention to thoseskilled in the art.

It will be understood that when an element is referred to as being“coupled” or “connected” to another element, it can be directly coupledor connected to the other element or intervening elements may also bepresent. In contrast, when an element is referred to as being “directlycoupled” or “directly connected” to another element, there are nointervening elements present. Like numbers refer to like elementsthroughout. As used herein the term “and/or” includes any and allcombinations of one or more of the associated listed items.

In addition, spatially relative terms, such as “under”, “below”,“lower”, “over”, “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. It will beunderstood that the spatially relative terms are intended to encompassdifferent orientations of the device in use or operation in addition tothe orientation depicted in the figures. For example, if the device inthe figures is inverted, elements described as “under” or “beneath”other elements or features would then be oriented “over” the otherelements or features. Thus, the exemplary term “under” can encompassboth an orientation of over and under. The device may be otherwiseoriented (rotated 90 degrees or at other orientations) and the spatiallyrelative descriptors used herein interpreted accordingly.

Well-known functions or constructions may not be described in detail forbrevity and/or clarity.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises,”“includes,” “comprising,” and/or “including,” when used in thisspecification, specify the presence of stated features, integers, steps,operations, elements, and/or components, but do not preclude thepresence or addition of one or more other features, integers, steps,operations, elements, components, and/or groups thereof.

It is noted that any one or more aspects or features described withrespect to one embodiment may be incorporated in a different embodimentalthough not specifically described relative thereto. That is, allembodiments and/or features of any embodiment can be combined in any wayand/or combination. Applicant reserves the right to change anyoriginally filed claim or file any new claim accordingly, including theright to be able to amend any originally filed claim to depend fromand/or incorporate any feature of any other claim although notoriginally claimed in that manner. These and other objects and/oraspects of the present invention are explained in detail in thespecification set forth below.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art andwill not be interpreted in an idealized or overly formal sense unlessexpressly so defined herein.

In some embodiments, the term “substantially” when used in connectionwith a claimed angular relationship includes angles that are ±5° of theclaimed angular relationship. In some other embodiments, the term“substantially” when used in connection with a claimed angularrelationship includes angles that are ±3° of the claimed angularrelationship. For example, an object that extends in a direction that issubstantially perpendicular to an axis may form an angle with the axisthat is between 85 and 95° or between 87 and 93° in various embodiments.

A stab base assembly 10 according to some embodiments is illustrated inFIGS. 1-4. The assembly 10 includes a stab base housing 12. The housing12 includes first and second opposite sides 14, 16 and third and fourthopposite sides 18, 20. The first and second sides 14, 16 may be parallelor substantially parallel to one another. The third and fourth sides 18,20 may be parallel or substantially parallel to one another. The thirdand fourth sides 18, 20 may also be perpendicular or substantiallyperpendicular to each of the first and second sides 14, 16.

The stab base housing 12 may be formed of an electrically insulatingmaterial. According to some embodiments, the housing 12 is formed of apolycarbonate or a thermoplastic polycarbonate. The housing 12 may beformed of Lexan™ available from SABIC (e.g., Lexan 3412ECR).

A plurality of stabs (or stab conductors) are held by the housing 12 andextend away from the housing 12. As described in more detail below, thestabs 22, 24, 26, 32, 34, 36 may be L-shaped or substantially L-shapedand include first portions 22A, 24A, 26A, 32A, 34A, 36A and secondportions 22B, 24B, 26B, 32B, 34B, 36B. The first portions 22A, 24A, 26Aof the stabs 22, 24, 26 may extend away from the first side 14 of thehousing 12 and the first portions 32A, 34A, 36A of the stabs 32, 34, 36may extend away from the second side 16 of the housing 12.

As described in more detail below, the stabs 22, 24, 26 may be held inchannels 42, 44, 46 defined in the housing 12 and may extend out ofopenings 42 o, 44 o, 46 o at the end of the channels 42, 44, 46 at thefirst side 14 of the housing 12. Similarly, the stabs 32, 34, and 36 maybe held in channels 52, 54, 56 defined in the housing 12 and may extendout of openings 52 o, 54 o, 56 o at the end of the channels 52, 54, 56at the second side 16 of the housing 12.

The stabs 22, 24, 26, 32, 34, 36 may be formed of an electricallyconductive material. According to some embodiments, the stabs 22, 24,26, 32, 34, 36 are formed of or include copper or aluminum.

Each of the first portions 22A, 24A, 26A, 32A, 34A, 36A of the stabs 22,24, 26, 32, 34, 36 may include a tapered end portion 22 t, 24 t, 26 t,32 t, 34 t, 36 t such that the stab narrows in thickness from a centralportion of the stab first portion to a distal end thereof.

The housing 12 includes a top or upper portion 28 and a bottom or lowerportion 30. An opening 70 is defined in the upper portion 28 of thehousing 12. A ground stab (or ground conductor) 72 extends outwardly andupwardly from the opening 70. The ground conductor 72 extends upwardlyabove a top 29 of the housing 12. The ground conductor 72 may beresilient (e.g., allow some deformation in the upward and downwarddirections). The ground conductor 72 may be formed of any suitableelectrically conductive material, e.g., copper or aluminum.

Each stab conductor 22, 24, 26, 32, 34, 36 and the ground conductor 72may include a cable or wire lead 23, 25, 27, 33, 35, 37, 73 associatedtherewith. Each cable 23, 25, 27, 33, 35, 37, 73 may extend from itsassociated conductor to outside the housing 12 at the lower portion 30thereof. More specifically, each cable 23, 25, 27, 33, 35, 37, 73 mayinclude a first end that is attached (e.g., brazed, welded, mechanicallycrimped, etc.) to its associated conductor and a second, opposite endthat extends out the lower portion 30 of the housing 12 (e.g., out ofone or more openings at the lower portion 30 of the housing 12). Asdescribed in more detail below, the second end of each cable may beconnected to an enclosure that, along with the stab base assembly 10,forms a plug-in device or unit (e.g., the plug-in device or unit 120shown in FIG. 17).

The stabs 22, 24, and 32 may be phase conductors for a three-phasecircuit or system. For example, the stab 22 may be an A phase conductor,the stab 24 may be a B phase conductor, and the stab 32 may be a C phaseconductor.

The stabs 26, 34 and/or 36 may be omitted in some embodiments. Whereused, the stab 26 may be a ground conductor for a 200% ground rating.Where used, the stab 34 may be a neutral conductor. Where used incombination with the stab 34, the stab 36 may be a neutral conductor fora 200% neutral rating.

The stab base housing 12 may include at least one alignment feature,shown as first and second alignment tabs 64, 66. The first alignment tab64 may extend outwardly away from the first side 14 of the housing 12and a second alignment tab 66 may extend outwardly away from the secondside 16 of the housing 12. The first tab 64 may have a first length L1and the second tab 66 may have a second length L2. The second length L2may be greater than the first length L1.

A coupling feature, such as first and second flanges 76, 78 may resideat the lower portion 30 of the housing 12, typically below the alignmenttabs 64, 66. As illustrated, the first flange 76 extends outwardly awayfrom the third side 18 of the housing 12 and the second flange 78extends outwardly away from the fourth side 20 of the housing 12. Eachflange 76, 78 may have an aperture defined therein to facilitateconnection of the stab base assembly 10 to an enclosure (see, e.g., theaperture 76 a shown in FIG. 17).

The stab base housing 12 according to some embodiments is shown in moredetail in FIGS. 5-8. The housing 12 may be a two-piece housing andincludes a first housing portion 12A and a second housing portion 12B.The first housing portion 12A includes a plurality of first couplingfeatures 80 and the second housing portion 12B includes a plurality ofsecond coupling features 82. The first and second coupling features 80,82 are configured to cooperate such that the first and second housingportions 12A, 12B can be coupled together as shown in FIGS. 1-4. Forexample, the first coupling features 80 may include a plurality ofapertures 80 a and the second coupling features 82 may include aplurality of apertures 82 a that can be aligned with the first pluralityof apertures 80 a and a fastener (e.g., a polymeric fastener) may bereceived through the aligned apertures to couple the first and secondhousing portions 12A, 12B. Other coupling features are contemplated (asjust one example, one of the housing portions 12A, 12B may include oneor more receptacles and the other of the housing portions 12A, 12B mayinclude one or more plugs or posts that may be received in thereceptacles with an interference fit to couple the first and secondhousing portions 12A, 12B). The first and second housing portions 12A,12B may additionally or alternatively be coupled by adhesive bonding.

Referring to FIGS. 5 and 6, first housing portion 12A includes firstthrough sixth channel portions 42A, 44A, 46A, 52A, 54A and 56A.Referring to FIGS. 7 and 8, the second housing portion 12B includesfirst through sixth channel portions 42B, 44B, 46B, 52B, 54B and 56B.When the first and second housing portions 12A, 12B are coupled, thechannel portions 42A, 42B combine to define the first channel 42, thechannel portions 44A, 44B combine to define the second channel 44, thechannel portions 46A, 46B combine to define the third channel 46, thechannel portions 52A, 52B combine to define the fourth channel 52, thechannel portions 54A, 54B combine to define the fifth channel 54, andthe channel portions 56A, 56B combine to define the sixth channel 56(FIG. 16). One or more of the channels 42, 44, 46, 52, 54, 56 may beL-shaped or substantially L-shaped. The openings 42 o, 44 o, 46 o, 52 o,54 o and 56 o (FIGS. 1 and 2) are defined at the end of the channels 42,44, 46, 52, 54 and 56, respectively.

The first housing portion 12A includes a recess 70A at an upper portionthereof. First and second opposite groove portions 84A, 86A are definedin the first housing portion 12A adjacent the recess 70A. The secondhousing portion 12B includes a recess 70B at an upper portion thereof.First and second opposite groove portions 84B, 86B are defined in thesecond housing portion 12B adjacent the recess 70B. When the first andsecond housing portions 12A, 12B are coupled, the recesses 70A, 70Bcombine to define the opening 70 (FIG. 1), the first groove portions84A, 84B combine to define a first groove 84 adjacent the opening 70(FIG. 16), and the second groove portions 86A, 86B combine to define asecond groove 86 adjacent the opening 70 (FIG. 16). The grooves 84, 86can hold ends of the ground conductor 72 (FIG. 14).

One or more cavities or depressions 88A and a slot 90A may be defined inthe first housing portion 12A (FIG. 6). The cavities or depressions 88Aand slot 90A may be defined in a wall 18W at the third side portion 18of the stab base housing 12 (FIG. 4). One or more cavities ordepressions 88B and a slot 90B may be defined in the second housingportion 12B (FIG. 8). The cavities or depressions 88B and slot 90B maybe defined in a wall 20W at the fourth side portion 20 of the stab basehousing 12 (FIG. 4). When the first and second housing portions 12A, 12Bare coupled, the walls 18W and 20W face one another.

A cable or wire management member 92 is illustrated in FIGS. 9 and 10.The cable management member 92 includes a central portion or post 94 andfirst and second opposite lateral or side portions (or wings) 96, 98that extend outwardly away from the central portion 94. The centralportion 94 has a height or length L3 and the first and second sideportions 96, 98 may extend along the entire length L3 of the centralportion 94.

The central portion 94 defines a channel or passageway 94 c that extendsthe entire length L3 of the central portion 94. The central portion 94may be tubular.

The first side portion 96 includes a first face or surface 96 a and anopposite second face or surface 96 b. The first side portion 96 includesan outer edge 96 e. The second side portion 98 includes a first face orsurface 98 a and an opposite second face or surface 98 b. The secondside portion includes an outer edge 98 e.

The first side portion 96 includes a leg 96L that extends downwardlybelow the central portion 94 on one side of the central portion 94 andthe second side portion 98 includes a leg 98L that extends downwardlybelow the central portion 94 on the opposite side of the central portion94. A recess 100 may be defined between the legs 96L and 98L.

One or more projections 102A may be on the outer edge 96 e of the firstside portion 96 and one or more projections 102B may be on the outeredge 98 e of the second side portion 98. A foot 104A may be on the leg96L and a foot 104B may be on the leg 98L.

The cable management member 92 is held within an interior chamber 12 cof the stab base housing 12 (FIG. 16). More specifically, referring toFIGS. 5-10, the projection(s) 102A may be received in the depression(s)88A of the first housing portion 12A and the projection(s) 102B may bereceived in the depression(s) 88B of the second housing portion 12B.Also, the foot 104A may be received in the slot 90A of the first housingportion 12A and the foot 104B may be received in the slot 90B of thesecond housing portion 12B. These features along with the dimensions(e.g., width) of the housing 12 and the cable management member 92 mayallow the cable management member 92 to be held tightly in the interiorchamber 12 c of the housing 12.

With reference to FIGS. 4-10, the outer edge 96 e of the first sideportion 96 of the cable management member 92 may be at the third sideportion 18 of the housing 12 and the outer edge 98 e of the second sideportion 98 of the cable management member 92 may be at the fourth sideportion 20 of the housing 12. Therefore, the cable management member 92may extend from the third side portion 18 to the fourth side portion 20of the housing 12 in the interior cavity 12 c thereof.

As will be described in more detail below, the cable management member92 may facilitate guidance and/or management of one or more of thecables or wires extending from one or more of the stab conductors and/orfrom the ground conductor.

The stab conductor 22 is illustrated in FIG. 11. The stab conductors 22,24, 26, 32, 34, 36 may each have the same structure; accordingly, in theinterest of brevity, only the stab conductor 22 will be described indetail below.

As described above, the stab conductor 22 includes first and secondportions 22A, 22B. The first portion 22A may be perpendicular orsubstantially perpendicular to the second portion 22B. The stabconductor second portion 22B includes first and second opposite faces22B1 (FIG. 12A) and 22B2. The stab second portion 22B includes a loweredge 22BL and first and second opposite side edges 22BS1 and 22BS2.

Referring to FIG. 16, a first upwardly extending channel 42 is definedin part by a first vertical wall 42V1 and a second vertical wall 42V2(the channel 42 is further defined by a ledge 42C and a horizontal wall42D). The first vertical wall 42V1 is shorter than the second verticalwall 42V2 so that a vertical gap G is provided between the first andsecond vertical walls 42V1, 42V2.

With reference to FIGS. 11, 12A and 16, the stab conductor 22 is held inthe channel 42 with the second face 22B2 facing (and possibly abutting)the second vertical wall 42V2. A portion of the first face 22B1 faces(and possibly abuts) the first vertical wall 42V1. A lower portion ofthe first face 22B1 is exposed at the vertical gap G. This facilitateselectrical connection with the cable or lead wire as will be describedin more detail below.

It can be seen from FIG. 16 that the other (e.g., second through sixth)channels 44, 46, 52, 54, 56 have the same or substantially the samestructure as the channel 42. Therefore, it will be understood that thestab conductor 24 may be held in the channel 44, the stab conductor 26(where used) may be held in the channel 46, the stab conductor 32 may beheld in the channel 52, the stab conductor 34 (where used) may be heldin the channel 54, and/or the stab conductor 36 (where used) may be heldin the channel 56 in the same or substantially the same way as describedabove in connection with the stab conductor 22 and the channel 42.

The stab conductor 22 with the cable 23 or the stab conductor 32 withthe cable 33 is illustrated in FIG. 12A. The cable 23 or 33 includes aninner conductor 23 c or 33 c that is surrounded by an electricallyinsulating layer 23 i or 33 i. The cable 23 or 33 includes a first end23 ₁ or 33 ₁ and an opposite second end 23 ₂ or 33 ₂. The cable firstend 23 ₁ or 33 ₁ is electrically connected to the stab conductor 22 or32 by joining (e.g., brazing, welding, mechanically crimping, etc.) theinner conductor 23 c or 33 c with the first face 22B1 or 32B1 of thestab conductor 22 or 32. As illustrated, the cable 23 or 33 is joinedwith the stab conductor 22 or 32 in a way that the cable 23 or 33extends perpendicularly or substantially perpendicularly away from thesecond side edge 22BS2 or 32BS2 of the stab conductor second portion 22Bor 32B.

The stab conductor 24 with the cable 25 or the stab conductor 34 withthe cable 35 is illustrated in FIG. 12B. The cable 25 or 35 includes aninner conductor 25 c or 35 c that is surrounded by an electricallyinsulating layer 25 i or 35 i. The cable 25 or 35 includes a first end25 ₁ or 35 ₁ and an opposite second end 25 ₂ or 35 ₂. The cable firstend 25 ₁ or 35 ₁ is electrically connected to the stab conductor 24 or34 by joining (e.g., brazing, welding, mechanically crimping, etc.) theinner conductor 25 c or 35 c with the first face 24B1 or 34B1 of thestab conductor 24 or 34. As illustrated, the cable 25 or 35 is joinedwith the stab conductor 24 or 34 in a way that the cable 25 or 35extends perpendicularly or substantially perpendicularly away from thefirst side edge 24BS1 or 34BS1 of the stab conductor second portion 24Bor 34B.

The stab conductor 26 with the cable 27 or the stab conductor 36 withthe cable 37 is illustrated in FIG. 12C. The cable 27 or 37 includes aninner conductor 27 c or 37 c that is surrounded by an electricallyinsulating layer 27 i or 37 i. The cable 27 or 37 includes a first end27 ₁ or 37 ₁ and an opposite second end 27 ₂ or 37 ₂. The cable firstend 27 ₁ or 37 ₁ is electrically connected to the stab conductor 26 or36 by joining (e.g., brazing, welding, mechanically crimping, etc.) theinner conductor 27 c or 37 c with the first face 26B1 or 36B1 of thestab conductor 26 or 36. As illustrated, the cable 27 or 37 is joinedwith the conductor 26 or 36 in a way that the cable 27 or 37 extendsperpendicularly or substantially perpendicularly away from the loweredge 26BL or 36BL of the stab conductor second portion 26B or 36B.

Such an arrangement can facilitate efficient cable or wire management.With reference to FIGS. 9, 10 and 13, the uppermost cables 23, 33 can berouted along one of the side portions 96, 98 of the cable managementmember 92 and downwardly out of the housing 12 and the cables 25, 35 canbe routed along the other one of the side portions 96, 98 of the cablemanagement member 92 and downwardly out of the housing 12. In someembodiments, the cables 23, 25, 33, 35 can be coupled (e.g., adhered) tothe cable management member 92. The cables 27, 37 may be routeddownwardly out of the housing 12. By routing the cables in differentdirections on each side of the cable management member 92 as describedabove, issues such as tangling or twisting of the cables can be avoided.In addition, the design provides necessary creepage and clearancedistances between bare conductors.

It will be appreciated that alternative arrangements can provide thesame or similar cable management advantages. For example, the cable 23or 33 may be joined with the stab conductor 22 or 32 in a way that thecable 23 or 33 extends perpendicularly or substantially perpendicularlyaway from the first side edge 24BS1 or 34BS1 of the stab conductorsecond portion 22B or 32B. Similarly, the cable 25 or 35 may be joinedwith the stab conductor 24 or 34 in a way that the cable 25 or 35extends perpendicularly or substantially perpendicularly away from thesecond side edge 24BS2 or 34BS2 of the stab conductor second portion 24Bor 34B.

An example of the ground stab conductor 72 is illustrated in FIG. 14. Asshown, the ground stab conductor 72 includes a center portion 72C andfirst and second lateral or side portions 72S1, 72S2 that extend awayfrom opposite sides of the center portion 72C. The center portion 72Cextends upwardly above the first and second side portions 72S1, 72S2.The center portion 72C may be arcuate and/or may include a concave lowerface or surface 72CL and an opposite convex upper face or surface 72CU.

The ground stab conductor 72 with the cable 73 electrically connectedthereto is illustrated in FIG. 15. The cable 73 includes an innerconductor 73 c and an outer electrically insulating layer 73 i. Thecable 73 includes a first end 73 ₁ and an opposite second end 73 ₂. Thecable first end 73 ₁ is electrically connected to the ground stabconductor 72 by joining (e.g., brazing, welding, mechanically crimping,etc.) the inner conductor 73 c with the lower surface 72CL of the groundstab conductor 72.

Referring to FIGS. 9 and 13, the cable 73 associated with the groundstab conductor 72 is received in and through the channel 94 c of thecable management member 92 and extends outside the stab base housing 12at a bottom portion thereof. This further facilitates effective cablemanagement within the interior of the stab base housing 12.

Referring to FIGS. 14-16, the side portions 72S1, 72S2 of the groundstab conductor 72 are received in the opposed grooves 84, 86 at the topportion of the stab base housing 12. The center portion 72C of theground stab conductor 72 is received in the opening 70 at the top of thehousing 12 and extends above the top 29 of the housing 12 (FIG. 1). Asdescribed below, the ground conductor 72 is configured to contact anupper wall of a busway housing. The ground conductor 72 may be domeshaped. The ground conductor 72 may be resilient and configured todeflect upwardly and downwardly in response to contacting the buswayhousing. The ground conductor 72 may be formed of any suitableelectrically conductive material, e.g., copper or aluminum.

A plug-in device or unit 120 is illustrated in FIG. 17. The plug-indevice 120 includes the stab base assembly 10 coupled to a top of anenclosure 122 using the flanges 76, 78. The second ends 23 ₂, 25 ₂, 27₂, 33 ₂, 35 ₂, 37 ₂, 73 ₂ of the cables 23, 25, 27, 33, 35, 37, 73(FIGS. 12A-12C and 15) may extend into and be electrically connected tocomponents in the enclosure in an interior thereof. As described in moredetail below, the plug-in device 120 is configured to be received in andelectrically connected to a busway system. The plug-in device 120 maybe, for example, a bus plug, an outlet box or a tap off. The plug-indevice 120 may include a protective device (e.g., breaker or fused)switch 124.

The stab assembly 10 and the plug-in device 120 may be used with abusway assembly or system such as the busway or bus duct system assembly300 illustrated in FIG. 18. The busway assembly 300 includes first andsecond busway or bus duct sections 312, 314. A joint assembly 316 isdisposed between the first and second busway sections 312, 314 to couplethe busway sections 312, 314. The busway assembly 300 typically forms aportion of a larger busway system or busway run, and one or moreadditional busway sections, joint assemblies and/or other components maybe included in the larger busway system.

The busway section 312 is illustrated in FIG. 19. The busway section 314has substantially the same structure as the busway section 312;accordingly, in the interest of brevity, only the busway section 312will be described in detail below.

The busway section 312 includes a housing 318. The housing 318 may beformed of any suitable material such as, for example, aluminum.Referring to FIG. 20, the housing 318 is elongated and defines alongitudinal axis A1. The housing 318 has a length L4. The length L3 maybe between about 0.5 to 10 feet in various embodiments.

Referring to FIGS. 19-21, the housing 318 has a top or upper portion320, a bottom or lower portion 334, and first and second opposing sideportions 322, 324. A lower ledge 326 extends inwardly from each of theside portions 322, 324 and extends the length L4 of the housing 318. Thehousing side portions 322, 324 each include a channel 332.

The housing top portion 320 includes a pair of upper flanges 342 (e.g.,substantially L-shaped opposed flanges) that extend from a top or upperwall 321. The flanges 342 may be used for mounting or suspending thebusway section 312. A lower flange 344 (e.g., a substantially L-shapedflange) extends downwardly from each one of the ledges 326. The flanges344 may be shaped and configured to receive finger safe seals as well asaccess barriers, as will be described in more detail below.

A first one of the lower ledges 326 and a first one of the lower flanges344 define a first channel 336 at the first side 322 and the lowerportion 334 of the housing 318. A second one of the lower ledges 326 anda second one of the lower flanges 344 define a second channel 338 at thesecond side 324 and the lower portion 334 of the housing 318. The firstchannel 336 has a laterally extending first depth d1 and the secondchannel 338 has a laterally extending second depth d2. The second depthd2 of the second channel 338 may be greater (longer) than the firstdepth d1 of the first channel 336.

Referring again to FIG. 19, the busway section 312 includes first andsecond insulators 352, 354. The first and second insulators 352, 354 arereceived in the housing 318 at the first and second side portions 322,324, respectively (FIGS. 12 and 15). The insulators 352, 354 arecontinuous and may have the same length (L5 in FIG. 22) or about thesame length as the length L4 of the housing 318 (FIG. 20).

A perspective view of the insulator 352 is shown in FIG. 22 and an endview of the insulator 352 is shown in FIG. 23. When viewed from the end,the insulator 354 is a mirror image of the insulator 352. Accordingly,in the interest of brevity, only the insulator 352 will be described indetail below.

Referring to FIG. 22, the insulator 352 includes a top or upper portion356, a central or middle portion 358 and a bottom or lower portion 360.Referring to FIGS. 22 and 23, the insulator 352 includes an outer wall357 that extends from the upper portion 356 to the lower portion 360 ofthe insulator 352. The upper portion 356 includes an upper channel 368that is sized and configured to receive and/or hold a conductor or busbar. Inwardly extending projections 370, 372 define an opening 374 tothe channel 368. Each of the projections 370, 372 include a raisedportion 371, 373 such that the channel 368 narrows between the raisedportion 371, 373. The outer wall 357 and the projections 370, 372 definethe upper channel 368.

The central portion 358 of the insulator 352 includes a channel 378 thatis sized and configured to receive and/or hold a conductor or bus bar.Projections 380, 382 define an opening 384 to the channel 378. Each ofthe projections 380, 382 include a raised portion 381, 383 such that thechannel 378 narrows between the raised portion 381, 383. The outer wall357 and the projections 380, 382 define the central channel 368.

The lower portion 360 of the insulator 352 includes a channel 388 sizedand configured to receive and/or hold a conductor or a bus bar. Thechannel 388 may have the same shape and/or size as the channel 368and/or the channel 378. Projections 390, 392 define an opening 394 tothe channel 388. Each of the projections 390, 392 include a raisedportion 391, 393 such that the channel 388 narrows between the raisedportion 391, 393. The outer wall 357 and the projections 390, 392 definethe lower channel 388.

FIG. 24 is a perspective view illustrating the insulators 352, 354installed in the housing 318. Specifically, the insulator 352 isinstalled at the side portion 322 of the housing 318 and the insulator354 is installed at the opposite side portion 324 of the housing 318.The insulators 352, 354 may extend continuously along the housing 318(i.e., along the entire length L4 or substantially the entire length L4of the housing 318). In some embodiments, the insulators 352, 354 areslidingly received in the housing 318 in the position shown in FIG. 24.The insulators 352, 354 may be slidingly received in the housing 318 ina direction that is parallel or substantially parallel to the housinglongitudinal axis A1 (FIG. 20).

The housing 318 and the insulators 352, 354 are shaped and configuredand have features such that the insulators 352, 354 can be aligned withthe housing 318, guided into the housing 318 and/or held in place (e.g.,securely held in place) in the housing 318. These features, along withadditional details of the busway assembly 300, are described inco-pending and commonly owned U.S. patent application Ser. No.15/443,112 entitled “Busway Systems and Related Assemblies and Methods”(Attorney Docket No. 9060-355CTIP), filed Feb. 27, 2017, the disclosureof which is incorporated by reference herein in its entirety.

The insulators 352, 354 may be formed of any suitable electricallyinsulating material. According to some embodiments, the insulators 352,354 are formed of a polycarbonate or a thermoplastic polycarbonate. Theinsulators 352, 354 may be formed of Lupoy™ available from LG Chem(e.g., LG LUPOY NF 1005F03R).

Referring again to FIG. 19, the busway section 312 includes a pluralityof conductors or bus bars 410, 412, 414, 416, 418, 419. The conductorsor bus bars 410, 412, 414, 416, 418, 419 may be formed of any suitableelectrically conductive material; an exemplary suitable material iscopper or aluminum.

FIG. 25 is a perspective view of the bus bar conductor 410 and FIG. 26is an end view of the conductor 410. The conductors 412, 414, 416, 418and 419 are the same or substantially the same as the conductor 410;therefore, in the interest of brevity, only the conductor 410 will bedescribed in detail below.

The conductor 410 has a length L6. According to some embodiments, thelength L6 is less than the length L4 of the housing 318 (FIG. 20) and/orthe length L5 of the insulators 352, 354 (FIG. 22). According to someembodiments, the length L6 of the conductor 410 is about 1 to 2 inchesless than the length L4 of the housing 318 and/or the length L5 of theinsulators 352, 354. According to some embodiments, the length L6 of theconductor 410 is about 1 to 1.25 inches less than the length L4 of thehousing 318 and/or the length L5 of the insulators 352, 354.

Referring to FIG. 26, the conductor 410 may have a “butterfly” profile.More specifically, the conductor 410 includes a straight orsubstantially straight outer portion 410_O and opposite upper and lower(or first and second) curved or bent portions 410U, 410L. The upperportion 410U includes a first upper portion 410U1 that extends away fromthe outer portion 410_O and curves or bends downwardly and a secondupper portion 410U2 that extends away from the first upper portion 410U1and curves or bends upwardly. A contact surface 410S is defined betweenor at an interface of the first and second upper portions 410U1, 410U2(although it will be understood that the contact surface 410S may bedefined by a portion of the first upper portion 410U1 and/or a portionof the second upper portion 410U2). The second upper portion 410U2terminates at a first inner end 410I1 of the conductor 410.

Similarly, the lower portion 410L includes a first lower portion 410L1that extends away from the outer portion 410_O and curves or bendsupwardly and a second lower portion 410L2 that extends away from thefirst lower portion 410L1 and curves or bends downwardly. A contactsurface 410S is defined between or at an interface of the first andsecond lower portions 410L1, 410L2 (although it will be understood thatthe contact surface 410S may be defined by a portion of the first lowerportion 410L1 and/or a portion of the second lower portion 410L2). Thesecond lower portion 410L2 terminates at a second inner end 410I2 of theconductor 410.

The conductor outer portion 410_O and the upper and lower portions 410U,410L define a lengthwise channel 410 c. The channel 410 c tapersinwardly from the first and second inner ends 410I1, 410I2 to thecontact surface 410S of the conductor 410. In other words, the conductor410 includes a flared opening 410F to the channel 410 c. This mayfacilitate alignment and/or guidance for the insertion of a conductor orstab of a plug-in device to be received in the channel 410 c.

The conductor 410 includes the double-sided (or dual pressure) contactsurface 410S to provide increased contact surface area and/orcompressive force on conductors received in the channel 410 c of theconductor 410. As described in more detail herein, such conductors maybe associated with stab base assemblies and/or plug-in devices.

It will be appreciated that each of the conductors 412, 414, 416, 418,419 shares the same features and advantages described above in referenceto the conductor 410. For example, each of the conductors 412, 414, 416,418, 419 includes a double-sided contact surface 412S, 414S, 416S, 418S,419S, a channel 412 c, 414 c, 416 c, 418 c, 419 c, and a flared opening412F, 414F, 416F, 418F, 419F as described above.

Turning to FIG. 27, the conductors or bus bars are received in channelsdefined in the insulators 352, 354. The conductors 410 and 412 arereceived in the channels 368 and 378 of the insulator 352, respectively.The conductor 416 is received in the channel 368 of the insulator 354.In some embodiments, the conductor 414 is received in the channel 388 ofthe insulator 352. In some embodiments, the conductor 418 is received inthe channel 378 of the insulator 354. In some embodiments, the conductor419 is received in the channel 388 of the insulator 354.

The conductors 410, 412 and 416 may be phase conductors or bus bars(e.g., the conductor 410 may be an A phase conductor, the conductor 412may be a B phase conductor and the conductor 416 may be a C phaseconductor), the conductor 414 may be a ground conductor or bus bar, andthe conductor 418 may be a neutral conductor or bus bar. Such aconfiguration can be used for a three phase busway system, althoughother configurations are contemplated including single phase and twophase busway systems.

In some embodiments, the conductor 414, the conductor 418 and/or theconductor 419 may be omitted. For example, the conductor 414 may beomitted and the housing 318 may provide standard ground. Rails 264 ofjoint cover assembly 250 (FIG. 18) may serve as ground blocks (e.g.,T-shaped ground blocks) to create and maintain a housing ground path.That is, when the joint cover 250 is installed for operation (e.g., whenjoint cover housing 256 is secured over the joint assembly 316 by, forexample, receiving fasteners 262 through apertures 260 and the rails 264with the rails received in the channels 332 of the busway housings), theground block or rails 264 may form a housing ground path betweenadjacent busway sections 312, 314. Where used, the conductor 414 may bea ground conductor or bus bar for a 200% ground rating.

Where used, the conductor 418 may be a neutral conductor or bus bar andmay provide standard neutral. Where used in combination with theconductor 418, the conductor 419 may be a neutral conductor or bus barfor a 200% neutral rating.

The conductors 410, 412, 414, 416, 418, 419 may all be the same size andshape. This may reduce manufacturing costs and provide reliability andrepeatability of fit within the insulator channels and placement of thecontact surface area for a conductor to be coupled thereto.

The upper and lower portions of each conductor (e.g., the upper andlower portions 410U, 410L of the conductor 410 shown in FIG. 26) may beresilient and able to flex. The raised portions of the insulatorprojections (e.g., the raised portions 371, 373 of the projections 370,372 shown in FIG. 23) may be adjacent and/or abut the upper and lowerportions of the conductor (e.g., the upper and lower portions 410U, 410Lof the conductor 410 shown in FIG. 26) to help ensure that the upper andlower portions are spaced apart the correct distance.

The busway section 312 (e.g., the housing 318 and/or the insulators 352,354) defines a channel 420 at the lower portion 334 of the housing 318in which plug-in devices can be received and engage the conductors 410,412, 414, 416, 418, 419. The channel 420 is continuous along the lengthL4 of the housing 318 (FIG. 20) such that the busway section 312 can beused with a continuous plug-in busway system.

Referring back to FIG. 19, the busway section 312 may include first andsecond finger safe lip seals 422, 424. As illustrated in FIG. 27, theseals 422, 424 are shaped and configured to be received along the lowerflanges 344 of the housing 318. The seals 422, 424 are formed of anelectrically insulating material (e.g., a polycarbonate or athermoplastic polycarbonate material such as LG LUPOY NF 1005F03R) andprovide a safety feature to help prevent or reduce the likelihood ofcontact with the housing 318 and/or the conductors 410, 412, 414, 416,418, 419 during installation or maintenance or when installing a plug-indevice in the channel 420.

The seals 422, 424 may be used so that the busway system complies withsafety regulations such as the Underwriters Laboratories (UL) “FingerSafe Probe” standard. In some embodiments, the seals 422, 424 may beomitted and the design may include component interface dimensions tocomply with the UL “Finger Safe Probe” standard.

The stab base assembly 10 and the plug-in device 120 may be electricallyconnected to the busway as will now be described. Referring to FIG. 28,the stab base assembly 10 is positioned below the opening 420 of thehousing 318 of the busway section 312. Referring to FIGS. 28 and 29, thestab base assembly 10 is moved or urged upwardly through the opening 420to a first position in the busway section 312 or busway housing 318. Inthe first position, the first and second stab conductors 22, 24 (FIG. 1)and the stab conductor 32 (FIG. 2) each extend away from the stab basehousing 12 in a direction that is parallel or substantially parallel tothe longitudinal axis A1 of the busway housing 318 (FIG. 20). Whereused, the stab conductors 26, 34, and/or 36 also extend away from thestab base housing 12 in a direction that is parallel or substantiallyparallel to the longitudinal axis A1 of the busway housing 318 in thefirst position.

Also in the first position, the ground stab conductor 72 contacts theupper wall 321 of the busway housing 318. This helps ensure that thestab base assembly 10 and the plug-in device 120 are grounded beforebeing electrically connected to the busway.

The stab base assembly 10 is then rotated to a second positionillustrated in FIG. 30. The stab base assembly 10 and the plug-in device120 are electrically connected to the busway in the second position.More specifically, the stab conductor 22 is electrically connected withthe bus bar conductor 410, the stab conductor 24 is electricallyconnected with the bus bar conductor 412 and the stab conductor 32 iselectrically connected with the bus bar conductor 418 in the secondposition. In addition, where used, the stab conductor 26 is electricallyconnected with the bus bar conductor 414, the stab conductor 34 iselectrically connected with the bus bar conductor 418, and/or the stabconductor 36 is electrically connected with the bus bar conductor 419 inthe second position. Referring to FIG. 27, the configuration of theinsulators 352, 354 with the projections and the shape of the conductors410, 412, 414, 416, 418, 419 may facilitate guiding the stabs intocontact with the bus bar conductors.

More specifically, referring to FIGS. 27 and 30, the stab conductors 22,24, 26, 32, 34 and/or 36 may be slidingly received in the channels 410c, 412 c, 414 c, 416 c, 418 c and/or 419 c, respectively, of the buswaysection conductors 410, 412, 414, 416, 417, 418 and/or 419 when the stabbase assembly 10 is rotated from the first to the second position. Thetapered portions 22 t, 24 t, 26 t, 32 t, 34 t and 36 t at one end of thestab conductors 22, 24, 26, 32, 34 and 36 may help facilitate insertioninto the busway section conductor channels 410 c, 412 c, 414 c, 416 c,418 c and 419 c when the stab base assembly 10 is rotated from the firstposition to the second position. Each stab conductor is slidinglyreceived between the upper and lower portions of the correspondingbusway section conductor and makes contact with the contact surfacedefined thereby. For example, the stab conductor 24 is received in thechannel 412 c defined by the busway section conductor 412. The stabconductor 24 is received between the upper and lower portions 412U, 412Lof the conductor 412 and contacts the contact surface 412S defined bythe upper and lower portions 412U, 412L of the conductor 412.

The ground stab conductor 70 continues to contact the upper wall 321 ofthe busway housing 318 when the stab base assembly 10 is rotated fromthe first position to the second position. As described above, theground conductor 72 may be resilient and configured to translate up anddown as needed during rotation to maintain contact with the upper wall321 of the busway housing 318.

The configuration of the alignment tabs 64, 66 of the stab base housing12 and/or the channels 336, 338 of the busway housing 318 help ensureelectrical polarity between the proper phasing when the stab baseassembly 10 is rotated from the first position to the second position.More specifically, the relatively longer second alignment tab 66 can bereceived in the relatively deeper channel 338 when the stab baseassembly 10 is rotated from the first position to the second position.However, the second alignment tab 66 is too long to be received in theshallower channel 336.

Put another way, the stab base assembly 10 can only be rotated in onerotational direction from the first position shown in FIG. 29 to reachthe second position shown in FIG. 30. As illustrated, the stab baseassembly can only be rotated in the counterclockwise direction to reachthe second position such that the stab conductors are electricallyconnected with the bus bar conductors of the busway. This prevents anelectrical connection with incorrect polarity. Referring again to FIGS.1 and 2, the stab base housing 12 includes a first rounded portion 80above the first alignment tab 64 and a second rounded portion 82 abovethe second alignment tab 66. The first and second rounded portions 80,82 may be concave portions. The first and second rounded portions 80, 82facilitate sliding of the first and second alignment tabs 64, 66 in thefirst and second busway housing channels 336, 338, respectively, whenthe stab base assembly 10 is rotated from the first position to thesecond position. The rounded portions 80, 82 may help prevent the stabbase housing 12 from binding in the busway housing 318 during rotation.

The alignment feature of the stab base housing may take other forms. Asjust one example, the stab base housing 12 may include channels,recesses or slots defined therein and the busway housing 318 may includetabs configured to be received in the channels of the stab base housing12. The tabs and the channels may be sized to allow rotation in only onerotational direction.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention as defined inthe claims. The invention is defined by the following claims, withequivalents of the claims to be included therein.

What is claimed is:
 1. A plug-in device for use with a busway systemcomprising a busway housing defining a longitudinal axis, the plug-indevice comprising: a stab base housing having first and second oppositesides; one or more stab conductors extending out of and away from thestab base housing at the first side of the stab base housing; one ormore stab conductors extending out of and away from the stab basehousing at the second side of the stab base housing; and a groundconductor extending upwardly from an upper portion of the stab basehousing; wherein the stab base housing is configured to be receivedthrough an opening at a bottom portion of the busway housing andpositioned in a first position with each stab conductor extending awayfrom the stab base housing in a direction substantially parallel to thelongitudinal axis of the busway housing and with the ground conductorcontacting a top wall of the busway housing; wherein the stab basehousing is configured to be rotated from the first position to a secondposition with each stab conductor extending away from the stab basehousing in a direction substantially perpendicular to the longitudinalaxis of the busway housing and with the ground conductor contacting thetop wall of the busway housing; wherein the ground conductor isresilient and configured to translate up and down relative to the stabbase housing in response to contact with the top wall of the buswayhousing.
 2. The plug-in device of claim 1 wherein the stab base housingcomprises an alignment feature configured to allow rotation of the stabbase housing from the first position to the second position in only onerotational direction.
 3. The plug-in device of claim 2 wherein: thealignment feature comprises a first alignment tab on the first side ofthe stab base housing and a second alignment tab on the second side ofthe stab base housing; and the first alignment tab has a first lengthand the second alignment tab has a second length that is greater thanthe first length.
 4. The plug-in device of claim 3 wherein the stab basehousing comprises a first concave rounded portion above the firstalignment tab and a second concave rounded portion above the secondalignment tab.
 5. The plug-in device of claim 1 wherein: the one or morestab conductors extending out of and away from the stab base housing atthe first side of the stab base housing comprise first and second phaseconductors; and the one or more stab conductors extending out of andaway from the stab base housing at the second side of the stab basehousing comprise a third phase conductor.
 6. The plug-in device of claim5 wherein the one or more stab conductors extending out of and away fromthe stab base housing at the first side of the stab base housingcomprise a ground conductor for a 200% ground rating.
 7. The plug-indevice of claim 1 wherein: the one or more stab conductors extending outof and away from the stab base housing at the first side of the stabbase housing comprise first and second phase conductors; and the one ormore stab conductors extending out of and away from the stab basehousing at the second side of the stab base housing comprise a thirdphase conductor and a neutral conductor.
 8. The plug-in device of claim7 wherein: the neutral conductor is a first neutral conductor; and theone or more stab conductors extending out of and away from the stab basehousing at the second side of the stab base housing comprise a secondneutral conductor for a 200% neutral rating.
 9. The plug-in device ofclaim 1 wherein the stab base housing includes a coupling feature at alower portion thereof for coupling the stab base housing to anenclosure.
 10. The plug-in device of claim 9 wherein: the plug-in deviceincludes the enclosure; a cable extends from each stab conductor tooutside the stab base housing at the lower portion thereof; and eachcable is electrically connected to components in the enclosure.
 11. Abusway system comprising: a busway section comprising a busway housingdefining a longitudinal axis; and a plug-in device comprising: a stabbase housing having first and second opposite sides; one or more stabconductors extending out of and away from the stab base housing at thefirst side of the stab base housing; and one or more stab conductorsextending out of and away from the stab base housing at the second sideof the stab base housing; wherein the stab base housing is configured tobe received through an opening at a bottom portion of the busway housingand positioned in a first position with each stab conductor extendingaway from the stab base housing in a direction substantially parallel tothe longitudinal axis of the busway housing; wherein the stab basehousing is configured to be rotated from the first position to a secondposition with each stab conductor extending away from the stab basehousing in a direction substantially perpendicular to the longitudinalaxis of the busway housing; wherein the stab base housing comprises analignment feature configured to allow rotation of the stab base housingfrom the first position to the second position in only one rotationaldirection.
 12. The system of claim 11 wherein: the alignment featurecomprises a first alignment tab on the first side of the stab basehousing and a second alignment tab on the second side of the stab basehousing; and the first alignment tab has a first length and the secondalignment tab has a second length that is greater than the first length.13. The system of claim 12 wherein: the busway housing includes a firstchannel and a second channel at the bottom portion of the buswayhousing; the first channel has a first depth that is less than thesecond length and the second channel has a second depth that is greaterthan the first depth, the first and second depths extending in adirection substantially perpendicular to the longitudinal axis of thebusway housing; and the first alignment tab is received in the firstchannel and the second alignment tab is received in the second channelwhen the stab base housing is in the second position.
 14. The system ofclaim 12 wherein the stab base housing comprises a first concave roundedportion above the first alignment tab and a second concave roundedportion above the second alignment tab.
 15. The system of claim 11wherein: the plug-in device comprises a ground conductor comprising aconvex upper surface that extends upwardly from the upper portion of thestab base housing; and the ground conductor is configured to resilientlycontact an upper wall of the busway housing in the first position and/orin the second position.
 16. The system of claim 11 wherein: the buswayhousing comprises first and second opposite side portions; a firstinsulator held in the first side portion of the busway housing, thefirst insulator holding one or more bus bar conductors; a secondinsulator held in the second side portion of the housing, the secondinsulator holding one or more bus bar conductors; and each stab baseconductor is electrically connected to one of the bus bar conductors inthe second position.
 17. The system of claim 16 wherein: each bus barconductor held in the first insulator comprises an upper portion and anopposite lower portion; each bus bar conductor held in the secondinsulator comprises an upper portion and an opposite lower portion; inthe second position, each one of the stab conductors extending out ofand away from the stab base housing at the first side of the stab basehousing is received between and contacts the upper and lower portions ofone of the bus bar conductors held in the first insulator to beelectrically connected therewith; and in the second position, each oneof the stab conductors extending out of and away from the stab basehousing at the second side of the stab base housing is received betweenand contacts the upper and lower portions of one of the bus barconductors held in the second insulator to be electrically connectedtherewith.
 18. The system of claim 11 wherein each of the stabconductors comprises an end portion that is tapered such that the endportion narrows in thickness from a central portion to an end of thestab conductor.
 19. A plug-in device for use with a busway systemcomprising a busway housing defining a longitudinal axis, the plug-indevice comprising: a stab base housing having first and second oppositesides; one or more stab conductors extending out of and away from thestab base housing at the first side of the stab base housing; and one ormore stab conductors extending out of and away from the stab basehousing at the second side of the stab base housing; wherein the stabbase housing is configured to be received through an opening at a bottomportion of the busway housing and positioned in a first position witheach stab conductor extending away from the stab base housing in adirection substantially parallel to the longitudinal axis of the buswayhousing; wherein the stab base housing is configured to be rotated fromthe first position to a second position with each stab conductorextending away from the stab base housing in a direction substantiallyperpendicular to the longitudinal axis of the busway housing; whereineach of the stab conductors comprises an end portion that is taperedsuch that the end portion narrows in thickness from a central portion toan end of the stab conductor.
 20. The plug-in device of claim 19 furthercomprising a ground conductor extending from the stab base housing,wherein the ground conductor is resilient and configured to moverelative to the stab base housing in response to contact with at leastone wall of the busway housing in the first position and/or the secondposition.